Analysis of C-shaped micro-polished surface cutting of generator rotor core in wind power generation
At a time when competition in the wind power industry is fierce, the key to whether a wind turbine can operate stably and efficiently lies in the accuracy of its core components. In particular, the quality of the fine processing of the generator rotor core directly determines the power generation efficiency and equipment life. The C-type micro-bright surface spark wire cutting processing technology is becoming a "magic weapon" to overcome this problem.
As the core component of wind turbines, the rotor core of the generator requires extremely high manufacturing precision. In actual production, C-type micro-bright surface spark wire cutting processing technology is often used to cut and form rotor core punching sheets. These punching sheets are usually made of high-permeability silicon steel sheets and have complex shapes. Not only do they have multiple teeth for embedding armature windings, but they also need to ensure that the flatness and surface roughness of the punching sheets meet the standards to reduce hysteresis and eddy current losses.
Traditional processing methods are difficult to meet the dual requirements of precision and surface quality when processing rotor core punching sheets. However, C-type micro-bright surface spark wire cutting stands out with its unique advantages. On the one hand, it can control the dimensional accuracy of the punching sheet within ±0.01mm by accurately controlling the pulse discharge parameters, effectively ensuring the compatibility of the tooth slot and the winding; on the other hand, its "micro-bright surface" characteristics make the surface roughness Ra value of the processed punching sheet reach ≤ 0.7-1.4 μm , greatly reducing the electromagnetic loss on the core surface. In a case, by introducing this technology, the overall performance of the generator rotor core was improved by 12%, and the equipment failure rate was reduced by 18%.
However, there are many difficulties in the C-shaped micro-bright surface spark wire cutting of the generator rotor core. Silicon steel sheets are brittle and prone to edge collapse and cracking during cutting, which places extremely strict demands on the control of cutting process parameters. The complex tooth shape makes cutting path planning more difficult, and any slight deviation will affect the subsequent winding assembly. Long-term cutting may also lead to electrode wire loss, which in turn affects processing accuracy.
Zhikai CNC has been deeply engaged in the research and development of cutting technology for many years. In response to the above problems, it has developed a high-performance C-type micro-bright surface spark wire cutting equipment, which can not only perfectly solve the problem of fine processing of generator rotor cores, but also excel in the processing of other wind power components. For example, in the cutting of tower flanges and the forming of blade connectors, Zhikai CNC's equipment can help improve both production efficiency and product quality with precise control and stable performance.
When traditional wire cutting encounters efficiency bottlenecks, Zhikai's third-generation intelligent knife repair technology is saving 15% of molybdenum wire loss for 3,576 customers. We have already answered your processing pain points with modular design: the self-developed constant temperature primary color processing power supply system can handle complex materials, and the rapid response ensures 7 × 24h stable operation. You can get the "White Paper on Optimization of Parameters for Medium Wire Cutting" for free by consulting now. Zhikai's team of engineers is in place to customize a combination of cost reduction and efficiency improvement for you within three minutes. "Friends from Jianning County, Youxi County, Jiangle County, Shaxian District, Ninghua County, Taining County, Datian County, Yong'an City, Qingliu County, Mingxi County, Sanyuan District and other places are welcome to consult.
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